Transmission, disassemblingshane/stasj/pics/motor/dokumentasjon/A4-S4_B5/Tra… · Transmission,...

34-43

Transmission, disassembling and assembling Disassembly sequence Page 34-55 .

Transmission overview

1 - 1st gear

2 - 2nd gear

3 - 3rd gear

4 - 4th gear

5 - 5th gear

6 - Reverse gear

Removing and installing reverse idler gear Page 35-44

7 - Tapered roller bearing

Adjusting Page 39-39

of 27Transmission, disassembling and assembling

11/19/2002http://127.0.0.1:8080/audi/servlet/Display?action=Goto&type=repair&id=AUDI.B5.TM02.34.5

34-44

8 - Torsen differential

Can only be serviced by manufacturer

Removing and installing together with cover Page 34-39

9 - Bearing

10 - Bearing

11 - Flange shaft

12 - Torsen differential cover

13 - Compression spring

Between Torsen differential and hollow shaft

14 - Input shaft

Disassembling and assembling Page 35-1

15 - Transmission cover



34-45

16 - Transmission housing

17 - Ball bearing

Adjusting thickness Input shaft, adjusting 5-17

18 - Differential

Removing and installing Page 39-16


19 - Drive pinion

Disassembling and assembling drive pinion and hollow shaft Page 35-21

20 - Radial tapered roller bearing


21 - Hollow shaft

Disassembling and assembling drive pinion and hollow shaft Page 35-21

Page 3 of 27Transmission, disassembling and assembling


34-46

Assembly overview

I - Input shaft ball bearing and multi-function switch, removing and installing

Page 34-47

II - Input shaft, drive pinion, hollow shaft, selector rods, transmission cover and Torsen differential cover, removing and installing Page 34-51



34-47

Input shaft ball bearing and multi-function switch, removing and installing


With differential and flange shafts

Removing and installing flange shafts Page 39-1

Removing and installing differential Page 39-16

Removing and installing speedometer Vehicle Speed Sensor (VSS) Page 39-13

Removing and installing speedometer drive gear Page 39-14

Breather installation position Fig. 1

2 - Torx bolt

Always replace

35 Nm (26 ft lb)

Self-locking

3 - Guide sleeve

Installed with O-ring and seal for input shaft Page 30-20

4 - Dished washer



Smaller diameter (convex side) faces guide sleeve



34-48

5 - Circlip

Determining thickness and input shaft, adjusting Page 35-17

6 - Input shaft ball bearing


7 - Circlip

Determining thickness and input shaft, adjusting Page 35-17

8 - Input shaft




Servicing input shaft ball bearing Page 35-1

9 - Socket-head bolt

25 Nm (18 ft lb)

10 - Locking plate

For multi-function switch

11 - Multi-function switch



34-49

12 - Multi-function switch harness connector

13 - Socket-head bolt

10 Nm (7 ft lb)

14 - Cover for shift rod


15 - Gear lock for 5th and reverse gear




34-50

After pressing in, the breather must project 21 mm (0.827 in.) out of the housing .

Fig. 1 Breather installation position



34-51

Input shaft, drive pinion, hollow shaft, shift rods, transmission cover and Torsen differential cover, removing and installing


2 - Input shaft



Servicing input shaft bearings Page 35-1

3 - Shift rod with shift fork for 3rd and 4th gear


Replacing bushings Page 34-84

4 - Left stop bolt

40 Nm (30 ft lb)

5 - Sealing washer



34-52

6 - Relay shaft

Installation position Page 34-79

7 - Sealing washer

8 - Right stop bolt

40 Nm (30 ft lb)

9 - Shift rod


Replacing shift rod sealing washer Page 34-79

10 - Shift detent


11 - Torx bolt

25 Nm (18 ft lb)

With shoulder to secure shift detent spring

12 - Shift rod with 1st/2nd/5th and reverse gear shift fork


Removing and installing ball sleeve Page 34-83



34-53

13 - Drive pinion with hollow shaft



Servicing drive pinion and hollow shaft bearings Page 35-21

14 - Transmission cover

Removing and installing oil collector tray Fig. 1

15 - Torx bolt

22 Nm (16 ft lb)

16 - Compression spring

17 - Torsen differential cover

Removing and installing with transmission installed Page 34-39

Removing and installing Torsen differential from cover Page 34-68

Servicing cover Page 34-68

18 - Torx bolt

22 Nm (16 ft lb)



34-54

Removing

Installing

Fig. 1 Removing and installing oil collector tray

- Turn oil collector tray (arrow) and pull out.

- Push oil collector tray into transmission, until it snaps in.

Oil collector tray faces upward in transmission cover.



34-55

Input shaft ball bearing, multi-function switch, input shaft, drive pinion, shift rods, transmission cover and Torsen differential cover, removing and installing

Notes:

To remove the above-mentioned components it is not necessary to remove the differential.

Removal is only necessary when adjustments have to be performed Page 39-37 , list of adjustments

Special tools and equipment

VW309 holding plate

VW353 transmission support

3235 press device

VAG1306 drip tray

VAG1582 taper roller bearing puller



VAG1582/3 attachment to VAG1582



34-56

Removing

- Place drip tray below transmission.

- Drain gear oil.

- Secure transmission to assembly stand Page 34-30 .

Notes:

- Remove clutch release lever -A- with release bearing.

Before removing the guide sleeve, slide a shrink tube over the input shaft splines to protect the seal.

Remove the seal in the guide sleeve Page 30-20 .

- Remove guide sleeve -B-.

- Remove dished washer -C-.

- Remove circlip -D- in front of input shaft ball bearing.

- Note thickness of circlip, if ball bearing, drive axle or transmission housing is not replaced.



34-57

- Pull input shaft ball bearing out of transmission housing.

- Remove circlip (arrow) behind input shaft ball bearing.

- Note thickness of circlip, if ball bearing, drive axle or transmission housing are not replaced.



34-58

- Remove cover -A- together with Torsen differential from transmission cover -B-.

- Remove compression spring from drive pinion.

- Remove transmission cover -B- from transmission housing -C-.

- Remove bolts (arrows) and pull out multi-function switch.



34-59

- Remove relay shaft stop bolts (arrows) items 4, 8 Page 34-51 , and Page 34-52 .

- Unbolt shift detent (arrow) and swing it out.



34-60

- Input shaft -A-, drive pinion -B-, relay shaft -C-, selector rods -D- with shift rod and selector forks -E- must all be carefully pulled out together.



34-61

Installing

Note:

If the input shaft ball bearing, the input shaft or the transmission housing are replaced, it is necessary to re-determine the thickness of the circlips for the input shaft first, input shaft, adjusting Page 35-17 .

- For easier installation of following components, swing transmission housing into position shown.

Note:

The relay shaft -C- and the shift rod can also be installed later if necessary Page 34-62 , Illustration V34-1816 and Page 34-63 , illustration V34-2120

- Assemble input shaft -A-, drive pinion -B-, relay shaft -C-, selector rods -D- with shift rod and selector forks -E-.

- Install these components into transmission housing as a set.



34-62

Position of shift mechanism in transmission.

Note:

Illustration is shown without the drive axle and pinion.

1 - Shift fork 5th and reverse gears

2 - Shift fork 3rd and 4th gears

3 - Shift fork 1st and 2nd gears

4 - Relay shaft

5 - Shift detent

6 - Shift rod

- Move transmission housing and engage 3rd gear (direction of arrow).



34-63

- Install relay shaft -A-.

- Place inner shift rod -B- sideways into mounting hole in transmission housing and assemble into mounting eye.

- Carefully turn shift rod in direction of arrow.

- Insert shift detent and tighten bolt (arrow) securely.



34-64

- Install relay shaft stop bolts (arrows).

- Replace O-ring for multi-function switch.

- Carefully insert multi-function switch and tighten (arrows).



34-65

- Make sure dowel sleeves for transmission cover -A- are installed in transmission housing -B- (arrows).

- Install transmission cover onto transmission housing.

- Make sure dowel sleeves for cover -A- are installed in transmission cover -B- (arrows).

- Install compression spring -C-.

- Install Torsen differential cover -A- onto transmission cover -B-.



34-66

- Install rear circlip (arrow) for ball bearing onto input shaft.

- Slide ball bearing onto input shaft.

Closed side of ball cage faces toward transmission housing.

- Press in ball bearing.

- Slide thrust piece -A- of press device onto input shaft.

- Position press device behind splines for clutch plate.

- Screw in bolts -B- and tighten slightly.

The bolts bear against the indentations in thrust piece -A-.

- Press in ball bearing onto seat by alternately tightening bolts -B- (1/2-turn at a time) until stop is reached.



34-67

Notes:

- Install front circlip -D- for input shaft ball bearing.

- Install dished washer -C-.

Position: convex side faces guide sleeve -B-.

Before installing guide sleeve, cover splines on input shaft with a shrink-fit hose to protect the seal.

Installing seal in guide sleeve Page 30-20 .

- Install guide sleeve -B- for clutch release bearing.

- Install clutch release lever -A- and clutch release bearing.



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